Komatsu HYDRAULIC EXCAVATOR PC138US-11 Shop Manual SEN06662-07 PDF

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Komatsu HYDRAULIC EXCAVATOR PC138US-11 Shop Manual SEN06662-07 – PDF DOWNLOAD

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Komatsu HYDRAULIC EXCAVATOR PC138US-11 Shop Manual SEN06662-07 – PDF DOWNLOAD

Language : English
Pages :3244
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HYDRAULIC EXCAVATOR PC138US-11 Shop Manual SEN06662-07 – PDF DOWNLOAD

SERIAL NUMBERS 51618 and up

Foreword, Safety, Basic Information
How to Read the Shop Manual
• Some of the attachments and optional parts in this shop manual are not available in some regions. If you
wish to use such items, consult Komatsu.
• Materials and specifications are subject to change without notice.
• Drawings and photos in this shop manual show the typical model. Some of them will possibly show a different
shape from the actual forklift truck.
Composition of Shop Manual
This shop manual contains the necessary technical information for services done in a shop. These are classified
as follows to make the manual easier to use.
00 Index and Foreword
This section explains the index, foreword, safety and basic information.
01 Specification
This section explains the specifications of the forklift truck.
10 Structure and Function
This section explains the structure and function of each system. The “Structure and Operation” section is a useful
reference material for you to understand the structure of each device better. It also is useful to do a troubleshooting.
20 Standard Value Table
This section explains the standard values for new forklift truck and judgement criteria for testing, adjusting, and
troubleshooting. This standard value table is used to give the standard values in testing and adjusting and to
judge parts in troubleshooting.
30 Testing and Adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and methods to
adjust each part. The standard values and judgement criteria for troubleshooting in “Testing and Adjusting” are
given in the standard value table. Use them together.
40 Troubleshooting
This section explains how to find out defective parts when a failure occurs and how to do remedies. The troubleshooting
is divided by failure modes.
50 Disassembly and Assembly
This section explains the special tools and procedures to remove, install, disassemble, and assemble each
component, and the precautions required for safe work. In addition, tightening torques, and quantity and weight
of coating material, oil, grease, and coolant necessary for these works are also shown.
60 Maintenance Standard
This section explains the maintenance standard values of each device. The judgment criteria and remedies for
disassembly and maintenance are shown in the maintenance standard section.
80 Appendix
This chapter explains the items that follow.
• Devices which cannot be classified into sections are explained as others in this section. The structure, operation,
test, adjustment, and troubleshooting for those are explained together.
• This section explains the items, contents and criteria of the special self-imposed inspection.
90 Circuit Diagrams
This section gives hydraulic circuit diagrams and electrical circuit diagrams

TABLE OF CONTENTS:

Komatsu HYDRAULIC EXCAVATOR PC138US-11 Shop Manual SEN06662-07 – PDF DOWNLOAD

SERIAL NUMBERS 51618 and up

Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 21
Foreword, Safety, Basic Information 27
How to Read the Shop Manual 27
Safety Notice for Operation 29
Precautions to Prevent Fire 37
Procedures If Fire Occurs 39
Precautions When You Discard Waste Materials 40
Procedures for Exhaust Gas Regulations 41
Precautions for DEF 42
General Character and Precautions for Handling 42
Precautions When You Add 42
Precautions for Storage 42
Precautions for Fire Hazard and Leakage 42
Other Precautions 42
Store DEF 43
Precautions When You Handle Hydraulic Equipment 44
Precautions When You Disconnect and Connect Pipings 47
Precautions When You Handle Electrical Equipment 54
Precautions When You Handle Fuel System Equipment 56
Precautions When You Handle Intake System Equipment 57
Practical Use of KOMTRAX 58
Disconnect and Connect Push-Pull Type Coupler 59
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 59
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 60
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 61
Precautions for Disconnection and Connection of Connectors 63
Disconnect and Connect Deutsch Connector 67
How to Disconnect and Connect Slide Lock Type Connector 68
Disconnect and Connect Connector with Lock to Pull 70
Disconnect and Connect Connector with Lock to Push 71
Disconnect and Connect Connector with Housing to Rotate 73
How to Read the Codes for Electric Cable 74
Explanation of Terms for Maintenance Standard 78
Standard Tightening Torque Table 81
Conversion Table 88
01 Specification 93
Table of Contents 94
Abbreviation List 95
Specifications 101
Specification Drawing 101
Specification Drawing PC138US-11 101
Working Range Drawings 103
Working Range Drawings: PC138US-11 103
Specifications 104
Specifications PC138US-11 104
Weight Table 108
Weight Table PC138US-11 108
Table of Fuel, Coolant, and Lubricants 110
10 Structure and Function 111
Table of Contents 112
Abbreviation List 115
Urea SCR System 121
Layout Drawing of Urea SCR System 121
Urea SCR System Diagram 123
Function of Urea SCR System 124
Function of DEF System 124
Inducement Strategy 126
Function that Calls for Attention of the Operator for Urea SCR System to Stay Functional 139
Component Parts of Urea SCR System 146
DEF Mixing Tube 146
SCR Assembly 146
DEF Tank 149
DEF Pump 151
DEF Injector 152
DEF Hose 153
DEF Tank Heating Valve 154
Boot-up System 155
Layout Drawing of Boot-up System 155
System Operating Lamp System 156
System Diagram of System Operating Lamp System (Machine with KOMTRAX Terminal) 156
System Diagram of System Operating Lamp System (Machine with Gateway Function Controller) 156
Function of System Operating Lamp System (Machine with KOMTRAX Terminal) 156
Function of System Operating Lamp System (Machine with Gateway Function Controller) 157
Battery Disconnect Switch 159
Function of Battery Disconnect Switch 159
Engine System 160
Layout Drawing of Engine System 160
Engine Control System 162
System Diagram of Engine Control System (Machine with KOMTRAX Terminal) 162
System Diagram of Engine Control System (Machine with Gateway Function Controller) 163
Function of Engine Control System (Machine with KOMTRAX Terminal) 163
Function of Engine Control System (Machine with Gateway Function Controller) 165
Auto-Deceleration System 168
System Diagram of Auto-Deceleration System 168
Function of Auto-Deceleration System 168
Operation of Auto-Deceleration System 169
Engine Automatic Warm-up System 170
System Diagram of Engine Automatic Warm-up System 170
Function of Engine Automatic Warm-up System 170
Overheat Prevention System 172
Function of Overheat Prevention System 172
Turbocharger Protection System 174
Function of Turbocharger Protection System 174
Automatic Idle Stop System 175
Automatic Idle Stop System Diagram (Machine with KOMTRAX Terminal) 175
System Diagram of Automatic Idle Stop System (Machine with Gateway Function Controller) 175
Function of Automatic Idle Stop System 176
Component Parts of Engine System 179
PTO 179
Variable Flow Turbocharger 179
EGR System 183
EGR Valve 185
EGR Cooler 186
KCCV System 188
KCCV Ventilator 190
Exhaust Throttle Valve 192
KDOC 193
Cooling System 195
Layout Drawing of Cooling System 195
Specifications of Cooling System 196
Control System 197
Layout Drawing of Control System (Machine with KOMTRAX Terminal) 197
Layout Drawing of Control System (Machine with Gateway Function Controller) 199
Machine Monitor System 201
System Diagram of Machine Monitor System (Machine with KOMTRAX Terminal) 201
System Diagram of Machine Monitor System (Machine with Gateway Function Controller) 202
Function of Machine Monitor System 203
KomVision System 204
Layout Drawing of KomVision System 204
System Diagram of KomVision System 206
Function of KomVision System 206
KOMTRAX System 208
KOMTRAX System Diagram (Machine with KOMTRAX Terminal) 208
System Diagram of KOMTRAX System (Machine with Gateway Function Controller) 208
Function of KOMTRAX System 209
Component Parts of Control System 210
Machine Monitor 210
KomVision Controller 224
KomVision Camera 228
KOMTRAX Terminal 228
Gateway Function Controller 230
Communication Terminal 233
Pump Controller 235
Resistor for PC-EPC Valve 239
CAN Terminating Resistor 239
Engine Controller 241
Fuel Control Dial 247
Hydraulic System 249
Layout Drawing of Hydraulic System 249
CLSS 251
Structure of CLSS 251
Function of CLSS 252
Engine and Pump Combined Control System 254
Engine and Pump Combined Control System Diagram 254
Function of Engine and Pump Combined Control System 255
Component Parts of Hydraulic System 259
Hydraulic Tank 259
Main Pump 261
Control Valve 285
Work Equipment System 342
Layout Drawing of Work Equipment System 342
Structure of Valve Control 345
PPC Lock System 346
System Diagram of PPC Lock 346
Function of PPC Lock System 346
Work Equipment and Travel Automatic Lock System 347
System Diagram of Lock Lever Automatic Lock System 347
Function of Work Equipment and Travel Automatic Lock System 347
Operation of Lock Lever Automatic Lock System 348
Attachment Oil Flow Adjuster System 349
Attachment Oil Flow Adjuster System Diagram 349
Function of Attachment Oil Flow Adjuster System 350
Quick Coupler Control Valve System 351
Quick Coupler Control Valve System Diagram 351
Function of Quick Coupler Control Valve System 351
Operation of Quick Coupler Control Valve System 351
Component Parts of Work Equipment System 352
Work Equipment and Swing PPC Valve 352
1st-Line Attachment PPC Valve (with EPC Valve) 356
Blade PPC Valve 362
Solenoid Valve 365
Variable Back Pressure Solenoid Valve 369
Quick Coupler Control Valve 370
Multi-Control Valve 371
Arm Dump Quick Return Valve 372
Pilot Circuit Accumulator 375
Attachment Circuit Accumulator (For Low Pressure Circuit) 376
Swing System 377
Layout Drawing of Swing System 377
Swing Control System Diagram 379
Function of Swing Control System 379
Component Parts of Swing System 382
Swing Motor 382
Swing Machinery 391
Swing Circle 392
Travel System 394
Layout Drawing of Travel System 394
System Diagram of Travel Control System 396
Function of Travel Control System 396
Component Parts of Travel System 400
Travel Motor 400
Travel PPC Valve 413
Center Swivel Joint 417
Undercarriage and Frame 419
Layout Drawing of Undercarriage 419
Specifications of Undercarriage 419
Idler Cushion 420
Structure of Idler Cushion 420
Specifications of Idler Cushion 420
Work Equipment 421
Structure of Work Equipment 421
Function of Work Equipment 422
Work Equipment Clearance Adjustment Shim 423
Function of Work Equipment Clearance Adjustment Shim 423
Bucket Clearance Adjustment Shim 424
Function of Bucket Clearance Adjustment Shim 424
CAB Related Parts 425
ROPS CAB 425
Structure of ROPS CAB (Machine with KOMTRAX Terminal) 425
Structure of ROPS CAB (Machine with Gateway Function Controller) 426
Function of ROPS CAB 426
CAB Mount 427
Structure of CAB Mount 427
Function of CAB Mount 427
Remove Wiring Harness Out of Cab 429
20 Standard Value Table 431
Table of Contents 432
Abbreviation List 433
Standard Value Table for Engine 439
Standard Value Table for Engine: PC138US-11 439
Standard Value Table for Machine 443
Standard Value Table for Machine: PC138US-11 443
Machine Posture and Procedures to Measure Performance 457
30 Testing and Adjusting 461
Table of Contents 462
Precautions Before Work 465
Abbreviation List 466
Related Information on Testing and Adjusting 472
Differences In Machine Monitor Symbols 472
Tools for Testing and Adjusting 473
Sketch of Tools for Testing and Adjusting 480
Engine and Cooling System 482
Examine Engine Speed 482
How to Examine Engine Speed 482
Examine Exhaust Gas Color 485
How to Examine Exhaust Gas Color with the Handy Smoke Checker 485
How to Examine Exhaust Gas Color with Smoke Meter 486
Examine the Clearance of Exhaust Throttle Valve 487
Measure Clearance of the Exhaust Throttle Valve 487
Examine and Adjust Valve Clearance 490
Check Valve Clearance 490
Adjust Valve Clearance 491
Examine Compression Pressure 492
How to Examine Compression Pressure 492
Examine Blowby Pressure 495
How to Examine Blowby Pressure 495
Examine Engine Oil Pressure 497
How to Examine Engine Oil Pressure 497
Visual Check Inside of EGR Valve 499
How to do the Visual Check Inside of EGR Valve 499
Clean Inside of EGR Valve 501
How to Clean Inside of EGR Valve 501
Examine Fuel Pressure 504
How to Examine Fuel Pressure 504
Examine Fuel Return Rate and Leakage 506
How to Examine Fuel Return Rate and Leakage 507
Bleed Air from Fuel System 510
How to Bleed Air from Fuel System 510
Examine Fuel Circuit for Leakage 512
How to Examine Fuel System for Leakage 512
Handle Cylinder Cut-out Mode Operation 514
Handle No-Injection Cranking Operation 515
Examine and Adjust Air Conditioner Compressor Belt Tension 516
How to Examine Air Conditioner Compressor Belt 516
How to Adjust Air Conditioner Compressor Belt 516
Examine Alternator Belt 518
How to Examine Alternator Belt 518
Examine Automatic Tensioner 519
How to Examine Automatic Tensioner 519
Examine Cooling Fan Speed 521
How to Examine Cooling Fan Speed 521
Write Injector Compensation Value to Engine Controller 522
Write Injector Compensation Value 522
Examine SCR Related Functions 528
Examine DEF Pump Raised Pressure 531
Examine Injection Volume from DEF Injector 533
Examine DEF Line Heater Relay 1 537
Examine DEF Line Heater Relay 2 540
Examine DEF Pump Heater Relay 543
Examine DEF Tank Heater Valve 546
Examine SCR Denitration Efficiency 550
Clean DEF Tank 553
How to Clean DEF Tank 553
Bleed Air from Coolant Circuit of DEF Tank 558
How to Bleed Air from Coolant Circuit of DEF Tank 558
Clean DEF Pump 560
How to Clean DEF Pump 560
Power Train 566
Examine Swing Circle Bearing Clearance 566
How to Examine Swing Circle Bearing Clearance 566
Undercarriage and Frame 567
Examine and Adjust Track Tension 567
How to Examine Track Tension 567
How to Adjust Track Tension 567
Hydraulic System 569
Release Remained Pressure in Hydraulic Circuit 569
How to Release Remained Pressure from Hydraulic Tank 569
How to Release Remained Pressure in Hydraulic Cylinder Circuit 569
How to Release Remained Pressure from Swing Motor Circuit 571
How to Release Remained Pressure from Travel Motor Circuit 571
Examine and Adjust Oil Pressure in Work Equipment, Swing, Travel, and Blade Circuits 572
How to Examine Oil Pressure in Work Equipment, Swing, Travel, and Blade Circuits 572
How to Adjust Oil Pressure in Work Equipment, Swing, Travel, and Blade Circuits 578
Examine Oil Pressure of Control Circuit 581
Examine Oil Pressure in Control Circuit 581
Examine and adjust oil pressure in pump PC control circuit 583
How to Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 583
How to Examine PC-EPC Valve Outlet Pressure 584
How to Adjust Oil Pressure in Pump PC Control Circuit 585
Examine and Adjust Oil Pressure in Pump LS Control Circuit 587
Examine LS Differential Pressure with Machine Monitor 587
Examine LS Differential Pressure by Testing Tool 589
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 590
Adjust LS Valve 592
Examine Outlet Pressure of Solenoid Valve 593
How to Examine Outlet Pressure of Solenoid Valve 593
Operating Condition of Solenoid Valve 594
How to Examine Outlet Pressure in Variable Back Pressure Solenoid Valve 595
Operating Condition of Variable Back Pressure Solenoid Valve 597
Examine PPC Valve Outlet Pressure 598
Examine Outlet Pressure in PPC Valve 598
Adjust Play of Work Equipment and Swing PPC Valves 600
How to Adjust Play of Work Equipment and Swing PPC Valves 600
Examine and Adjust Travel Deviation 601
How to Examine Travel Deviation 601
Adjust Travel Deviation 601
Examine Parts Which Cause Hydraulic Drift of Work Equipment 604
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 604
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 604
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 605
Examine Oil Leakage 606
How to Examine Oil Leakage from Boom Cylinder 606
How to Examine Oil Leakage from Arm Cylinder 607
How to Examine Oil Leakage from Bucket Cylinder 607
How to Examine Oil Leakage from Blade Cylinder 608
How to Examine Oil Leakage from Swing Motor 608
How to Examine Oil Leakage from Travel Motor 609
Bleed Air from Hydraulic System 610
How to Bleed Air from Hydraulic System 611
CAB Related Parts 614
Examine CAB Tipping Stopper 614
How to Examine Cab Tipping Stopper 614
How to Adjust Mirrors 615
Procedure to Adjust Machine Left Front Mirror (A) 615
Procedure to Adjust Machine Rear Mirror (B) 615
How to Examine and Adjust Slide Door 617
How to Examine and Adjust Slide Door When It is Closed and Locked 617
How to Examine and Adjust Slide Door When It is Open and Locked 629
Electrical System 642
Set and Operate Machine Monitor 642
Operator Mode 645
Function to Show Technician Identification Status Screen 645
Function to Show Operator Identification Input Screen 645
Examine Function by LCD (Liquid Crystal Display) 646
Examine Function of Service Meter 646
Service Mode 646
How to Operate Service Mode 646
How to See Pre-defined Monitoring Information 649
How to Examine Self-Define Monitor Information 655
Abnormality Record Menu 666
How to See Maintenance Record 670
Maintenance Mode Setting 671
Set Phone Number Entry 674
Default Menu 675
Diagnostic Tests Menu 683
Adjustment Menu 691
No-Injection Cranking Operation 704
KOMTRAX Settings Menu 705
Show Service Message 710
Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal) 712
Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal) 717
Start Up KOMTRAX System (Machine with Gateway Function Controller) 719
Stop Use of KOMTRAX System (Machine with Gateway Function Controller) 725
Adjust Rearview Camera Angle 727
How to Adjust Rearview Camera Angle 727
Adjust KomVision Camera Angle 730
How to Adjust KomVision Camera Angle 731
Adjust KomVision Related Function 733
Setting of KomVision (Main Setting) 733
Setting of KomVision (Camera Setting) 736
Setting of KomVision (Camera Calibration) 738
Set Region of Bluetooth(R) Compatible Radio 751
Set Region of Bluetooth(R) Compatible Radio 751
Handle Voltage Circuit of Engine Controller 753
Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal) 754
Handle Battery Disconnect Switch (Machine with Gateway Function Controller) 755
Examine Diodes 756
Examine Diodes by Digital Tester 756
How to Examine Diodes by Analog Tester 756
Pm Clinic 757
Pm Clinic Service 757
Pm Clinic Check Sheet: PC138US-11 758
40 Troubleshooting 767
Table of Contents 768
Precautions Before Work 778
Abbreviation List 779
Related Information to Troubleshooting 785
General Troubleshooting Points 785
Troubleshooting Points for Urea SCR System 786
Sequence of Events in Troubleshooting 798
Checks Before Troubleshooting 800
Inspection Procedure Before Troubleshooting 802
Walk-Around Check 802
Test in Accordance with Testing Procedure 804
Examine Fuel Prefilter 804
Examine Water Separator, Drain Water and Sediment 804
How to Replace Fuel Prefilter Cartridge 804
Examine Fuel Main Filter 806
Examine Engine Oil Level (Oil Quantity in Oil Pan) 807
Examine Oil Level in PTO Gear Case 808
Examine Coolant Level (Reservoir Tank) 809
Examine Air Cleaner Clogging 809
Clean Outer Element 810
Replace Element 812
Examine Hydraulic Oil Level 813
Examine Hydraulic Oil Strainer 815
Examine Hydraulic Oil Filter 815
Examine Oil Level in Swing Machinery Case 816
Examine Oil Level in Final Drive Case 817
Bleed Air from Fuel System 818
Bleed Air from Hydraulic System 818
How to Examine Electric Equipment 818
Preparation for Troubleshooting of Electrical System 823
Preparation for Troubleshooting of Machine Monitor 823
Preparation for Troubleshooting of Engine Controller 823
Preparation for Troubleshooting of Pump Controller 824
Preparation for Troubleshooting of KOMTRAX Terminal 824
Preparation for Troubleshooting of Gateway Function Controller 825
How to Disconnect and Connect Connector with a Special Lock 825
Procedure for Troubleshooting 830
Symptom and Troubleshooting Numbers 833
Information Shown in Troubleshooting Table 838
Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 840
Connector List and Layout (Machine with KOMTRAX Terminal) 843
Connector List and Layout (Machine with Gateway Function Controller) 856
Connector Contact Connection Table 869
T-Branch Box and T-Branch Adapter Table 909
Fuse Location Table (Machine with KOMTRAX Terminal) 915
Fuse Location Table (Machine with Gateway Function Controller) 918
Precautions When You Replace KDOC 921
Failure Code Table 922
Troubleshooting by Failure Code (Display of Code) 939
Failure Code [879AKA] 939
Failure Code [879AKB] 941
Failure Code [879BKA] 943
Failure Code [879BKB] 945
Failure Code [879CKA] 947
Failure Code [879CKB] 948
Failure Code [879DKZ] 949
Failure Code [879EMC] 952
Failure Code [879FMC] 953
Failure Code [879GKX] 954
Failure Code [989L00] 956
Failure Code [989M00] 957
Failure Code [989N00] 958
Failure Code [A1U0N3] 959
Failure Code [A1U0N4] 962
Failure Code [A900FR] 965
Failure Code [A900N6] 966
Failure Code [A900NY] 967
Failure Code [AA10NX] 968
Failure Code [AB00KE] 970
Failure Code [AQ10MB] 973
Failure Code [AQ10N3] 975
Failure Code [AS00R2] 977
Failure Code [AS00R3] 978
Failure Code [AS00R4] 979
Failure Code [AS00R5] 980
Failure Code [AS00R6] 981
Failure Code [AS00ZK] 982
Failure Code [AS10KM] 983
Failure Code [AS10NR] 984
Failure Code [AS10NT] 986
Failure Code [AU10QA] 987
Failure Code [B@BAZG] 988
Failure Code [B@BAZK] 989
Failure Code [B@BCNS] 991
Failure Code [B@HANS] 992
Failure Code [CA115] 994
Failure Code [CA122] 996
Failure Code [CA123]1000
Failure Code [CA131]1004
Failure Code [CA132]1007
Failure Code [CA144]1010
Failure Code [CA145]1014
Failure Code [CA153]1017
Failure Code [CA154]1021
Failure Code [CA187]1025
Failure Code [CA221]1027
Failure Code [CA222]1031
Failure Code [CA227]1034
Failure Code [CA234]1035
Failure Code [CA238]1037
Failure Code [CA239]1039
Failure Code [CA249]1041
Failure Code [CA256]1044
Failure Code [CA271]1047
Failure Code [CA272]1050
Failure Code [CA322]1052
Failure Code [CA324]1056
Failure Code [CA331]1060
Failure Code [CA332]1064
Failure Code [CA343]1068
Failure Code [CA351]1069
Failure Code [CA352]1070
Failure Code [CA356]1073
Failure Code [CA357]1076
Failure Code [CA386]1080
Failure Code [CA435]1081
Failure Code [CA441]1083
Failure Code [CA442]1086
Failure Code [CA449]1087
Failure Code [CA451]1088
Failure Code [CA452]1091
Failure Code [CA515]1094
Failure Code [CA516]1096
Failure Code [CA553]1099
Failure Code [CA555]1101
Failure Code [CA556]1103
Failure Code [CA559]1105
Failure Code [CA689]1111
Failure Code [CA691]1116
Failure Code [CA692]1119
Failure Code [CA697]1122
Failure Code [CA698]1123
Failure Code [CA731]1124
Failure Code [CA778]1127
Failure Code [CA1117]1134
Failure Code [CA1664]1136
Failure Code [CA1669]1139
Failure Code [CA1673]1141
Failure Code [CA1677]1143
Failure Code [CA1678]1145
Failure Code [CA1682]1147
Failure Code [CA1683]1155
Failure Code [CA1684]1158
Failure Code [CA1686]1161
Failure Code [CA1691]1163
Failure Code [CA1694]1167
Failure Code [CA1695]1172
Failure Code [CA1696]1173
Failure Code [CA1712]1176
Failure Code [CA1713]1180
Failure Code [CA1714]1183
Failure Code [CA1715]1185
Failure Code [CA1776]1187
Failure Code [CA1777]1190
Failure Code [CA1843]1194
Failure Code [CA1844]1197
Failure Code [CA1885]1201
Failure Code [CA1887]1204
Failure Code [CA1896]1207
Failure Code [CA1938]1211
Failure Code [CA1942]1214
Failure Code [CA1961]1216
Failure Code [CA2185]1217
Failure Code [CA2186]1219
Failure Code [CA2249]1221
Failure Code [CA2272]1222
Failure Code [CA2311]1226
Failure Code [CA2349]1227
Failure Code [CA2353]1230
Failure Code [CA2357]1233
Failure Code [CA2636]1235
Failure Code [CA2637]1239
Failure Code [CA2765]1242
Failure Code [CA2771]1243
Failure Code [CA2976]1251
Failure Code [CA3142]1255
Failure Code [CA3143]1256
Failure Code [CA3144]1257
Failure Code [CA3146]1261
Failure Code [CA3147]1262
Failure Code [CA3148]1263
Failure Code [CA3151]1267
Failure Code [CA3165]1275
Failure Code [CA3229]1279
Failure Code [CA3231]1283
Failure Code [CA3232]1287
Failure Code [CA3235]1292
Failure Code [CA3239]1296
Failure Code [CA3241]1300
Failure Code [CA3242]1304
Failure Code [CA3251]1308
Failure Code [CA3313]1312
Failure Code [CA3314]1314
Failure Code [CA3315]1315
Failure Code [CA3419]1319
Failure Code [CA3421]1321
Failure Code [CA3497]1323
Failure Code [CA3498]1324
Failure Code [CA3543]1325
Failure Code [CA3545]1333
Failure Code [CA3547]1336
Failure Code [CA3558]1338
Failure Code [CA3559]1341
Failure Code [CA3562]1344
Failure Code [CA3563]1347
Failure Code [CA3567]1352
Failure Code [CA3568]1356
Failure Code [CA3571]1363
Failure Code [CA3572]1366
Failure Code [CA3574]1369
Failure Code [CA3575]1374
Failure Code [CA3577]1377
Failure Code [CA3578]1380
Failure Code [CA3582]1383
Failure Code [CA3583]1394
Failure Code [CA3596]1397
Failure Code [CA3649]1403
Failure Code [CA3681]1406
Failure Code [CA3682]1413
Failure Code [CA3713]1420
Failure Code [CA3717]1424
Failure Code [CA3718]1426
Failure Code [CA3724]1428
Failure Code [CA3725]1429
Failure Code [CA3748]1432
Failure Code [CA3755]1436
Failure Code [CA3866]1439
Failure Code [CA3867]1444
Failure Code [CA3868]1448
Failure Code [CA3899]1453
Failure Code [CA3911]1456
Failure Code [CA3912]1461
Failure Code [CA3918]1464
Failure Code [CA3921]1467
Failure Code [CA3928]1469
Failure Code [CA3932]1470
Failure Code [CA3933]1473
Failure Code [CA3934]1476
Failure Code [CA3935]1480
Failure Code [CA3936]1483
Failure Code [CA4152]1485
Failure Code [CA4155]1490
Failure Code [CA4156]1493
Failure Code [CA4157]1497
Failure Code [CA4159]1500
Failure Code [CA4164]1502
Failure Code [CA4165]1505
Failure Code [CA4166]1508
Failure Code [CA4168]1510
Failure Code [CA4169]1513
Failure Code [CA4171]1516
Failure Code [CA4249]1520
Failure Code [CA4251]1523
Failure Code [CA4261]1526
Failure Code [CA4277]1530
Failure Code [CA4281]1534
Failure Code [CA4459]1540
Failure Code [CA4461]1543
Failure Code [CA4533]1548
Failure Code [CA4534]1549
Failure Code [CA4731]1551
Failure Code [CA4732]1553
Failure Code [CA4739]1555
Failure Code [CA4768]1557
Failure Code [CA4769]1560
Failure Code [CA4842]1563
Failure Code [CA4952] (Machine with KOMTRAX Terminal)1568
Failure Code [CA4952] (Machine with Gateway Function Controller)1570
Failure Code [CA5115]1572
Failure Code [CA5179]1576
Failure Code [CA5181]1579
Failure Code [CA5271]1582
Failure Code [CA5272]1585
Failure Code [CA5273]1588
Failure Code [CA5274]1591
Failure Code [CA5275]1593
Failure Code [CA5276]1596
Failure Code [CA5277]1599
Failure Code [CA5387]1601
Failure Code [CA5388]1605
Failure Code [CA5389]1608
Failure Code [CA5391]1613
Failure Code [CA5392]1619
Failure Code [CA5393]1621
Failure Code [CA5394]1624
Failure Code [CA5395]1627
Failure Code [CA5396]1630
Failure Code [CA5631]1632
Failure Code [CA5938]1634
Failure Code [D110KB]1636
Failure Code [D19JKZ]1638
Failure Code [D811MC] (Machine with KOMTRAX Terminal)1641
Failure Code [D811MC] (Machine with Gateway Function Controller)1642
Failure Code [D862KA] (Machine with KOMTRAX Terminal)1643
Failure Code [D862KA] (Machine with Gateway Function Controller)1644
Failure Code [D8ALKA] (Machine with KOMTRAX Terminal)1646
Failure Code [D8ALKA] (Machine with Gateway Function Controller)1649
Failure Code [D8ALKB] (Machine with KOMTRAX Terminal)1652
Failure Code [D8ALKB] (Machine with Gateway Function Controller)1654
Failure Code [D8AQKR] (Machine with KOMTRAX Terminal)1656
Failure Code [D8AQKR] (Machine with Gateway Function Controller)1661
Failure Code [D8G1KT]1666
Failure Code [D8G6KT]1667
Failure Code [DA20MC]1668
Failure Code [DA22KK]1669
Failure Code [DA25KP]1673
Failure Code [DA26KP]1678
Failure Code [DA29KQ]1680
Failure Code [DA2LKA] (Machine with KOMTRAX Terminal)1683
Failure Code [DA2LKA] (Machine with Gateway Function Controller)1686
Failure Code [DA2LKB] (Machine with KOMTRAX Terminal)1689
Failure Code [DA2LKB] (Machine with Gateway Function Controller)1691
Failure Code [DA2QKR] (Machine with KOMTRAX Terminal)1693
Failure Code [DA2QKR] (Machine with Gateway Function Controller)1700
Failure Code [DA2RKR] (Machine with KOMTRAX Terminal)1707
Failure Code [DA2RKR] (Machine with Gateway Function Controller)1714
Failure Code [DAF0KM]1721
Failure Code [DAF0MB]1722
Failure Code [DAF0MC]1723
Failure Code [DAF8KB]1724
Failure Code [DAF9KQ]1726
Failure Code [DAFGMC]1728
Failure Code [DAFLKA] (Machine with KOMTRAX Terminal)1729
Failure Code [DAFLKA] (Machine with Gateway Function Controller)1732
Failure Code [DAFLKB] (Machine with KOMTRAX Terminal)1735
Failure Code [DAFLKB] (Machine with Gateway Function Controller)1737
Failure Code [DAFQKR] (Machine with KOMTRAX Terminal)1739
Failure Code [DAFQKR] (Machine with Gateway Function Controller)1745
Failure Code [DAZ9KQ]1751
Failure Code [DAZQKR] (Machine with KOMTRAX Terminal)1753
Failure Code [DAZQKR] (Machine with Gateway Function Controller)1758
Failure Code [DB2QKR] (Machine with KOMTRAX Terminal)1763
Failure Code [DB2QKR] (Machine with Gateway Function Controller)1770
Failure Code [DB2RKR] (Machine with KOMTRAX Terminal)1777
Failure Code [DB2RKR] (Machine with Gateway Function Controller)1785
Failure Code [DB90MC]1793
Failure Code [DBP0KM]1794
Failure Code [DBP0KT]1795
Failure Code [DBPQKR] (Machine with KOMTRAX Terminal)1796
Failure Code [DBPQKR] (Machine with Gateway Function Controller)1802
Failure Code [DDNRKA]1808
Failure Code [DDNRKY]1811
Failure Code [DDNS00]1814
Failure Code [DFB1KZ]1816
Failure Code [DFB2KZ]1819
Failure Code [DFB3L8]1822
Failure Code [DFB4L8]1824
Failure Code [DFB5KZ]1826
Failure Code [DFB6KZ]1829
Failure Code [DGH2KA]1832
Failure Code [DGH2KB]1834
Failure Code [DHA4KA]1836
Failure Code [DHPAMA]1838
Failure Code [DHS3MA]1841
Failure Code [DHS4MA]1844
Failure Code [DHS8MA]1847
Failure Code [DHS9MA]1850
Failure Code [DHSAMA]1853
Failure Code [DHSBMA]1856
Failure Code [DHSCMA]1859
Failure Code [DHSDMA]1862
Failure Code [DHSFMA]1865
Failure Code [DHSGMA]1868
Failure Code [DHSHMA]1871
Failure Code [DHSJMA]1874
Failure Code [DHSKMA]1877
Failure Code [DHSLMA]1879
Failure Code [DKULKA]1881
Failure Code [DKULKB]1883
Failure Code [DKULKY]1885
Failure Code [DLM5KA]1887
Failure Code [DLM5MB]1891
Failure Code [DR10KA]1893
Failure Code [DR21KX]1897
Failure Code [DUMBKA] (Machine with KOMTRAX Terminal)1900
Failure Code [DUMBKA] (Machine with Gateway Function Controller)1903
Failure Code [DUMBKB] (Machine with KOMTRAX Terminal)1906
Failure Code [DUMBKB] (Machine with Gateway Function Controller)1908
Failure Code [DV20KB]1910
Failure Code [DW43KA]1912
Failure Code [DW43KB]1914
Failure Code [DW43KY]1916
Failure Code [DW45KA]1918
Failure Code [DW45KB]1922
Failure Code [DW45KY]1926
Failure Code [DW4CKY]1928
Failure Code [DW91KA]1930
Failure Code [DW91KB]1933
Failure Code [DW91KY]1935
Failure Code [DWA2KA]1937
Failure Code [DWA2KB]1940
Failure Code [DWA2KY]1942
Failure Code [DWJ0KA]1944
Failure Code [DWJ0KB]1947
Failure Code [DWJ0KY]1950
Failure Code [DWK2KA]1952
Failure Code [DWK2KB]1955
Failure Code [DWK2KY]1957
Failure Code [DWN5KA]1959
Failure Code [DWN5KB]1962
Failure Code [DWN5KY]1964
Failure Code [DWNSKA]1966
Failure Code [DWNSKB]1968
Failure Code [DWNSKY]1970
Failure Code [DXA8KA]1972
Failure Code [DXA8KB]1976
Failure Code [DXE4KA]1978
Failure Code [DXE4KB]1981
Failure Code [DXE4KY]1983
Failure Code [DY20KA]1985
Failure Code [DY20MA]1988
Failure Code [DY2CKB]1991
Failure Code [DY2DKB]1995
Failure Code [DY2EKB]1998
Failure Code [F311KA]2001
Failure Code [F311KB]2003
Failure Code [F312KA]2005
Failure Code [F312KB]2007
Failure Code [F313KA]2009
Failure Code [F313KB]2011
Failure Code [F314KA]2013
Failure Code [F314KB]2015
Failure Code [F316KB]2017
Failure Code [F316KY]2019
Failure Code [F318KB]2021
Failure Code [F318KY]2023
Failure Code [F31AKB]2025
Failure Code [F31AKY]2027
Failure Code [F31BKB]2029
Failure Code [F31BKY]2031
Failure Code [F31CKB]2033
Failure Code [F31CKY]2035
Failure Code [F31DKB]2037
Failure Code [F31DKY]2039
Failure Code [F31EKB]2041
Failure Code [F31EKY]2043
Failure Code [FS10ZE]2045
Troubleshooting of Electrical System (E-Mode)2046
Engine Does Not Start (Engine Does Not Crank)2046
Manual Preheating System Does Not Operate2052
While Preheating is in Operation, Preheating Monitor Does Not Come On2055
When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing2057
Engine Coolant Temperature Monitor Comes On in White While Engine is in Operation2060
Hydraulic Oil Temperature Monitor Comes On in White While Engine is in Operation2061
Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation2062
Charge Level Monitor Comes On in Red While Engine is in Operation2063
Fuel Level Monitor Comes On in Red While Engine is in Operation2064
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation2065
Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation2066
Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation2067
Fuel Gauge Does Not Move from Minimum or Maximum2068
Display of Fuel Gauge is Different from Actual Fuel Level2070
Engine Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum2071
Display of Engine Coolant Temperature Gauge is Different from Actual Coolant Temperature2072
DEF Level is Not Shown Correctly2073
Hydraulic Oil Temperature Gauge Does Not Move from Minimum or Maximum2076
Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature2078
Some Areas of Machine Monitor Screen are Not Shown2079
Function Switch Does Not Operate2080
Automatic Warm-up System Does Not Operate (in Cold Weather)2081
Auto-Deceleration Monitor Does Not Come On or Go Out While Auto-Deceleration Switch is Operated2082
Auto-Decelerator is Not Operated or Canceled with Lever2083
Work Mode Selector Screen is Not Shown While Work Mode Switch is Operated2084
When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed2085
Travel Speed Monitor Does Not Change While Travel Speed Switch is Operated2086
Travel Speed Does Not Change Even When You Change Travel Speed2087
Alarm Buzzer Does Not Stop2088
Service Meter is Not Shown While Starting Switch is in OFF Position2089
Service Mode Cannot be Selected2090
All Work Equipment, Swing, Travel Do Not Operate2091
All Work Equipment, Swing, Travel Cannot be Locked2094
Machine Does Not Swing While Swing Parking Brake Release Switch is Set to Release Position2096
While Swing Parking Brake Release Switch is Turned on, Swing Brake is Not Operated2098
Work Equipment Does Not Operate While Lock Lever Automatic Release Switch is in Release Position2100
Travel Alarm Does Not Operate During Travel2102
Travel Alarm Does Not Stop When Machine Stops2104
Horn Does Not Sound2105
Horn Does Not Stop2107
Wiper Monitor Does Not Come On or Go Out While Wiper Switch is Operated2108
Windshield Wiper Does Not Operate When Wiper Switch is Operated2109
When Window Washer Switch is Operated, Window Washer Does Not Operate2111
“Boom Raise” is Not Shown Correctly with Monitoring Function2112
“Boom Lower” is Not Shown Correctly with Monitoring Function2113
“Arm OUT” is Not Shown Correctly with Monitoring Function2114
“Arm IN” is Not Shown Correctly with Monitoring Function2115
Bucket DUMP is Not Shown Correctly with Monitoring Function2116
Bucket CURL is Not Shown Correctly with Monitoring Function2117
Swing is Not Shown Correctly with Monitoring Function2118
Travel is Not Shown Correctly with Monitoring Function2119
Service is Not Shown Correctly with Monitoring Function2120
Blade RAISE is Not Shown Correctly with Monitoring Function2123
Blade LOWER is Not Shown Correctly with Monitoring Function2124
KOMTRAX System Does Not Operate Correctly2125
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)2126
Information Shown in Troubleshooting Table (H-Mode)2126
Failure Mode and Cause Table2127
All Work Equipment, Swing and Travel Do Not Work2136
All Work Equipment, Swing, and Travel Lack Speed or Power2137
Fine Control Performance or Response is Unsatisfactory2139
Unusual Noise is Heard from Around Hydraulic Pump2140
Engine Speed Drops Largely or Engine Stops2141
Boom Speed or Power is Low2143
Arm Speed or Power is Low2146
Bucket Speed or Power is Low2149
Blade Speed or Power is Low2152
Work Equipment Does Not Move in Single Operation2154
Hydraulic Drift of Boom is Large2155
Hydraulic Drift of Arm is Large2156
Hydraulic Drift of Bucket is Large2157
Hydraulic Drift of Blade is Large2158
When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves2160
Time Lag of Work Equipment is Large2161
Attachment Circuit Cannot be Changed2162
Oil Flow in Attachment Circuit Cannot be Changed2163
In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower2164
In Mixed Operation of Swing and Travel, Travel Speed Falls Largely2165
In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low2166
Machine Does Not Travel Straight2167
Machine is Not Steered Well or Steering Power is Low2170
Travel Speed is Low2172
One of Tracks Does Not Run2174
Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast2176
Upper Structure Does Not Swing in Two Directions of Right and Left2177
Machine Swings Only in One Direction2178
Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left2179
Swing Acceleration or Swing Speed is Low in Only One Direction2180
Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)2181
Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction)2182
Shock is Large When Upper Structure Stops Swing Operation2183
Large Unusual Noise is Made When Upper Structure Stops Swing Operation2184
Swing Drift on a Slope is Large (While Swing Parking Brake is Applied)2185
Swing Drift on a Slope is Large (While Swing Parking Brake is Released)2186
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)2187
Unusual Noise is Heard from Around Fan2188
Troubleshooting of Engine (S-Mode)2189
Information Shown in Troubleshooting Table (S-Mode)2189
Engine Does Not Crank When Starting Switch is Turned to Start Position2190
Engine Cranks but No Exhaust Smoke Comes Out2191
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)2192
Engine Startability is Unsatisfactory2193
Engine Does Not Pick Up Smoothly2195
Engine Stops During Operation2197
Engine Does Not Rotate Smoothly2199
Engine Lacks Output (or Lacks Power)2200
Exhaust Smoke is Black2202
Engine Oil Consumption is Excessive2204
Engine Oil Becomes Dirty Quickly2205
Fuel Consumption is Excessive2206
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)2207
Engine Oil Pressure Drops2208
Fuel Mixes Into Engine Oil2209
Water Mixes Into Engine Oil (Milky)2210
Coolant Temperature Increases Too High (Overheat)2211
Unusual Noise is Heard2212
Vibration is Excessive2214
Air Cannot be Bled from Fuel Circuit2215
Active Regeneration is Done Frequently2216
Active Regeneration Continues Long2217
White Smoke is Exhausted During Active Regeneration2218
DEF Consumption is Excessive2219
There is an Unusual Smell (Irritating Odor)2221
Foreign Materials Enter DEF (DEF Increases)2222
50 Disassembly and Assembly2223
Table of Contents2224
Precautions Before Work2229
Abbreviation List2230
Related Information on Disassembly and Assembly2236
How to Read This Manual2236
Coating Materials List2237
Special Tool List2242
Sketches of Special Tools2258
Engine and Cooling System2261
Remove and Install Supply Pump Assembly (When Counterweight Assembly is Not Removed)2261
Remove Supply Pump Assembly (When Counterweight Assembly is Not Removed)2261
Install Supply Pump Assembly (When Counterweight Assembly is Not Removed)2266
Remove and Install Supply Pump Assembly (When Counterweight Assembly is Removed)2273
Remove Supply Pump Assembly (When Counterweight Assembly is Removed)2273
Install Supply Pump Assembly (When Counterweight Assembly is Removed)2275
Remove and Install Injector Assembly2279
How to Remove Injector Assembly2279
How to Install Injector Assembly2286
Remove and Install Cylinder Head Assembly2297
How to Remove Cylinder Head Assembly2297
How to Install Cylinder Head Assembly2312
Remove and Install EGR Valve Assembly2332
Remove EGR Valve Assembly2332
Install EGR Valve Assembly2334
Remove and Install EGR Cooler Assembly2336
How to Remove EGR Cooler Assembly2336
How to Install EGR Cooler Assembly2339
Remove and Install Starter Assembly2342
Remove Starting Motor Assembly2342
Install Starting Motor Assembly2346
Remove and Install Air Conditioner Compressor Belt2351
Remove Air Conditioner Compressor Belt2351
Install Air Conditioner Compressor Belt2352
Remove and Install Alternator Belt2354
Remove Alternator Belt2354
Install Alternator Belt2356
Remove and Install Automatic Tensioner2358
Remove Automatic Tensioner2358
Install Automatic Tensioner2358
Remove and Install Radiator Assembly2359
How to Remove Radiator Assembly2359
How to Install Radiator Assembly2361
Remove and Install Hydraulic Oil Cooler Assembly2365
How to Remove Hydraulic Oil Cooler Assembly2365
How to Install Hydraulic Oil Cooler Assembly2370
Remove and Install Aftercooler Assembly2375
Remove Aftercooler Assembly2375
Install Aftercooler Assembly2376
Remove and Install Fan Clutch Assembly2379
How to Remove Fan Clutch Assembly2379
How to Install Fan Clutch Assembly2385
Remove and Install Engine and Main Pump Assembly2393
Remove Engine and Main Pump Assembly2394
Install Engine and Main Pump Assembly2404
Remove and Install Engine Front Oil Seal2417
How to Remove Engine Front Oil Seal2417
How to Install Engine Front Oil Seal2418
Remove and Install Engine Rear Oil Seal2420
How to Remove Engine Rear Oil Seal2420
How to Install Engine Rear Oil Seal2421
Remove and Install Fuel Cooler Assembly2425
Remove Fuel Cooler Assembly2425
Install Fuel Cooler Assembly2427
Remove and Install KDOC Assembly2429
How to Remove KDOC Assembly2429
How to Install KDOC Assembly2433
Remove and Install KDOC and SCR Assembly2436
Remove KDOC and SCR Assembly2436
Install KDOC and SCR Assembly2443
Remove and Install Fuel Tank Assembly2450
Remove Fuel Tank Assembly2450
Install Fuel Tank Assembly2458
Remove and Install DEF Tank Assembly2465
How to Remove DEF Tank Assembly2465
How to Install DEF Tank Assembly2471
Remove and Install DEF Tank Sensor Flange Assembly2478
How to Remove DEF Tank Sensor Flange Assembly2478
How to Install DEF Tank Sensor Flange Assembly2484
Remove and Install DEF Tank Sensor2491
How to Remove DEF Tank Sensor2491
How to Install DEF Tank Sensor2492
Remove and Install DEF Tank Strainer2499
Remove DEF Tank Strainer2499
Install DEF Tank Strainer2499
Remove and Install SCR Assembly2500
How to Remove SCR Assembly2500
How to Install SCR Assembly2504
Remove and Install KDOC and SCR Assembly Bracket2509
Remove KDOC and SCR Assembly Bracket2509
Install KDOC and SCR Assembly Bracket2512
Remove and Install Bellows Pipe Assembly2517
Remove Bellows Pipe Assembly2517
Install Bellows Pipe Assembly2520
Remove and Install KCCV Assembly2524
Remove KCCV Assembly2524
Install KCCV Assembly2525
Remove and Install Exhaust Throttle Valve2527
Remove Exhaust Throttle Valve2527
Install Exhaust Throttle Valve2533
Remove and Install DEF Mixing Tube2539
Remove DEF Mixing Tube2539
Install DEF Mixing Tube2544
Remove and Install DEF Injector2548
Remove DEF Injector2548
Install DEF Injector2552
Remove and Install DEF Pump2557
Remove DEF Pump2557
Install DEF Pump2561
Remove and Install DEF Hose2565
Remove DEF Hose2565
Install DEF Hose2575
Remove and Install Air Cleaner Assembly2585
Remove Air Cleaner Assembly2585
Install Air Cleaner Assembly2587
Remove and Install Air Conditioner Compressor Assembly2591
Remove Air Conditioner Compressor Assembly2591
How to Install Air Conditioner Compressor Assembly2593
Remove and Install Air Conditioner Condenser Assembly2596
How to Remove Air Conditioner Condenser Assembly2596
How to Install Air Conditioner Condenser Assembly2597
Power Train2599
Remove and Install Travel Motor and Final Drive Assembly2599
Remove Travel Motor and Final Drive Assembly2599
Install Travel Motor and Final Drive Assembly2602
Disassemble and Assemble Travel Motor and Final Drive Assembly (Applicable Machine: 50001 to 54383)2605
How to Disassemble Travel Motor and Final Drive Assembly (Applicable Machine: 50001 to 54383)2615
How to Assemble Travel Motor and Final Drive Assembly (Applicable Machine: 50001 to 54383)2632
Disassemble and Assemble Travel Motor and Final Drive Assembly (Applicable Machine: 54384 and up)2649
How to Disassemble Travel Motor and Final Drive Assembly (Applicable Machine: 54384 and Up)2660
How to Assemble Travel Motor and Final Drive Assembly (Applicable Machine: 54384 and Up)2678
Remove and Install Swing Motor and Swing Machinery Assembly2698
Remove Swing Motor and Swing Machinery Assembly2698
Install Swing Motor and Swing Machinery Assembly2701
Disassemble and Assemble Swing Machinery Assembly2704
Disassemble Swing Machinery Assembly2704
Assemble Swing Machinery Assembly2707
Remove and Install Swing Circle Assembly2714
Remove Swing Circle Assembly2714
Install Swing Circle Assembly2715
Undercarriage and Frame2716
Separate and Connect Track Assembly2716
Separate Track Assembly2716
Install Track Assembly2718
Remove and Install Sprocket2721
Remove Sprocket2721
Install Sprocket2721
Remove and Install Idler and Idler Cushion Assembly2723
Remove Idler and Idler Cushion Assembly2723
Install Idler and Idler Cushion Assembly2723
Disassemble and Assemble Idler Assembly2725
Disassemble Idler Assembly2725
Assemble Idler Assembly2726
Disassemble and Assemble Idler Cushion Assembly2730
Disassemble Idler Cushion Assembly2730
Assemble Idler Cushion Assembly2732
Disassemble and Assemble Track Roller Assembly2735
Disassemble Track Roller Assembly2735
Assemble Track Roller Assembly2737
Remove and Install Revolving Frame Assembly2740
Remove Revolving Frame Assembly2740
Install Revolving Frame Assembly2743
Remove and Install Counterweight Assembly2746
Remove Counterweight Assembly2746
Install Counterweight Assembly2752
Hydraulic System2759
Remove and Install Center Swivel Joint Assembly2759
Remove Center Swivel Joint Assembly2759
Install Center Swivel Joint Assembly2762
Disassemble and Assemble Center Swivel Joint Assembly2767
Disassemble Center Swivel Joint Assembly2767
Assemble Center Swivel Joint Assembly2768
Remove and Install Hydraulic Tank Assembly2769
Remove Hydraulic Tank Assembly2769
How to Install Hydraulic Tank Assembly2773
Remove and Install Main Pump Assembly2778
Remove Main Pump Assembly2778
Install Main Pump Assembly2783
Remove and Install Control Valve Assembly2789
How to Remove Control Valve Assembly2790
How to Install Control Valve Assembly2799
Disassemble and Assemble Control Valve Assembly2810
Assemble Control Valve Assembly2810
Replace Pressure Reducing Valve Cartridge Assembly2813
Disassemble and Assemble Work Equipment PPC Valve Assembly2816
Disassemble Work Equipment PPC Valve Assembly2816
How to Assemble Work Equipment PPC Valve Assembly2817
Disassemble and Assemble Travel PPC Valve Assembly2819
Disassemble Travel PPC Valve Assembly2819
How to Assemble Travel PPC Valve Assembly2819
Work Equipment2821
Remove and Install Blade Assembly2821
Remove Blade Assembly2821
Install Blade Assembly2822
Remove and Install Work Equipment Assembly2824
Remove Work Equipment Assembly2825
Install Work Equipment Assembly2831
Disassemble and Assemble Work Equipment Cylinder Assembly2837
How to Disassemble Work Equipment Cylinder Assembly2838
How to Assemble Work Equipment Cylinder Assembly2840
CAB Related Parts2847
Remove and Install Operator Cab Assembly (Machine with KOMTRAX Terminal)2847
Remove Operator CAB Assembly (Machine with KOMTRAX Terminal)2847
Install Operator CAB Assembly (Machine with KOMTRAX Terminal)2851
Remove and Install Slide Door2856
How to Remove Slide Door2856
How to Install Slide Door2856
Remove and Install Operator Cab Glass (Adhered Glass)2858
Remove Operator CAB Glass (Adhered Glass)2859
Install Operator CAB Glass (Adhered Glass)2860
Remove and Install Front Window Assembly2869
Remove Front Window Assembly2869
Install Front Window Assembly2872
Remove and Install Floor Frame Assembly2873
How to Remove Floor Frame Assembly2873
How to Install Floor Frame Assembly2883
Remove and Install Air Conditioner Unit Assembly2894
Remove Air Conditioner Unit Assembly2894
Install Air Conditioner Unit Assembly2900
Remove and Install Operator Seat2906
Remove Operator’s Seat2906
Install Operator’s Seat2906
How to Remove and Install Seat Belt2908
How to Remove Seat Belt2908
How to Install Seatbelt2909
Remove and Install Work Equipment Control Lever Assembly2910
How to Remove Work Equipment Control Lever Assembly2910
How to Install Work Equipment Control Lever Assembly2916
Remove and Install Front Wiper Assembly2924
Remove Front Wiper Assembly2924
Install Front Wiper Assembly2929
Electrical System2937
Remove and Install Engine Controller Assembly2937
Remove Engine Controller Assembly2937
Install Engine Controller Assembly2939
Remove and Install Pump Controller Assembly2940
Remove Pump Controller Assembly2940
Install Pump Controller Assembly2942
Remove and Install KomVision Controller Assembly2945
Remove KomVision Controller Assembly2945
Install KomVision Controller Assembly2947
Remove and Install Machine Monitor Assembly2949
Remove Machine Monitor Assembly2949
Install Machine Monitor Assembly2952
Remove and Install Mass Air Flow and Temperature Sensor2956
How to Remove Mass Air Flow and Temperature Sensor2956
How to Install Mass Air Flow and Temperature Sensor2957
Remove and Install KCCV Crankcase Pressure Sensor2958
How to Remove KCCV Crankcase Pressure Sensor2958
How to Install KCCV Crankcase Pressure Sensor2960
Remove and Install SCR Temperature Sensor2962
Remove SCR Temperature Sensor2962
Install SCR Temperature Sensor2963
Remove and Install Rearview Camera2965
Remove Rearview Camera2965
Install Rearview Camera2966
Remove and Install KomVision Camera2968
Remove KomVision Camera2968
Install KomVision Camera2970
Remove and Install KOMTRAX Terminal Assembly2973
Remove KOMTRAX Terminal Assembly2973
Install KOMTRAX Terminal Assembly2975
Remove and Install Gateway Function Controller Assembly2977
How to Remove Gateway Function Controller Assembly2977
How to Install Gateway Function Controller Assembly2979
Remove and Install Communication Terminal Wiring Harness2981
Remove Communication Terminal Wiring Harness2981
Install Communication Terminal Wiring Harness2984
Remove and Install Communication Terminal2989
How to Remove Communication Terminal2989
How to Install Communication Terminal2990
60 Maintenance Standard2993
Table of Contents2994
Abbreviation List2995
Engine and Cooling System3001
Maintenance Standard for Engine Mount3001
Maintenance Standard for PTO3002
Maintenance Standard for Cooling System3003
Power Train3004
Maintenance Standard for Swing Circle3004
Maintenance Standard for Swing Machinery3005
Maintenance Standard for Sprocket3007
Undercarriage and Frame3008
Maintenance Standard for Track Frame and Idler Cushion3008
Maintenance Standard for Idler3010
Maintenance Standard for Track Roller3011
Maintenance Standard for Carrier Roller3012
Maintenance Standard for Track Shoes3013
Maintenance Standard for Triple Shoes3016
Maintenance Standard for Road Liner3017
Hydraulic System3018
Maintenance Standard for Hydraulic Tank3018
Maintenance Standard for Main Pump3019
Maintenance Standard for PC-EPC Valve3023
Maintenance Standard for Swing Motor3024
Maintenance Standard for Travel Motor (Applicable Machine: 50001 to 54383)3027
Maintenance Standard for Travel Motor (Applicable Machine: 54384 and up)3028
Maintenance Standard for Control Valve3029
Maintenance Standard for Work Equipment and Swing PPC Valve3040
Maintenance Standard for Blade PPC Valve3043
Maintenance Standard for Travel PPC Valve3045
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve)3048
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve3049
Maintenance Standard for Solenoid Valve3051
Maintenance Standard for Variable Back Pressure Solenoid Valve3054
Maintenance Standard for Attachment Circuit Selector Valve (For High Pressure)3055
Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure)3056
Maintenance Standard for Attachment Circuit Accumulator (For Low Pressure Circuit)3057
Maintenance Standard for Center Swivel Joint3058
Work Equipment3059
Maintenance Standard for Work Equipment Linkage3059
Dimensions of Arm3064
Dimensions of Bucket3066
Maintenance Standard for Boom Cylinder3068
Maintenance Standard for Arm Cylinder3069
Maintenance Standard for Bucket Cylinder3070
Maintenance Standard for Blade Cylinder3071
CAB Related Parts3072
Maintenance Standard for CAB Mount3072
80 Appendix3073
Table of Contents3074
Precautions Before Work3076
Abbreviation List3077
Air Conditioner System3083
Precautions for Refrigerant3083
Air Conditioner Component3084
Specifications of Air Conditioner3086
Structure and Function of Refrigeration Cycle3087
Outline of Refrigeration Cycle3088
Component Parts of Air Conditioner System3090
Air Conditioner Unit3090
Configuration Diagram of Air Conditioner Unit3090
Function of Air Conditioner Unit3092
Component Parts of Air Conditioner Unit3093
Function of Evaporator as Air Conditioner Unit Component3093
Function of Heater Core as Air Conditioner Unit Component3093
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component3093
Function of Servo Motor as Air Conditioner Unit Component3094
Structure of Expansion Valve as Air Conditioner Unit Component3095
Function of Expansion Valve as Air Conditioner Unit Component3095
Operate Expansion Valve as Air Conditioner Unit Component3095
Function of Dual Pressure Switch3096
Air Conditioner Controller3097
Structure of Air Conditioner Controller3097
Compressor3098
Structure of Compressor3098
Specifications of Compressor3098
Function of Compressor3098
Condenser3099
Structure of Condenser3099
Specifications of Condenser3099
Function of Condenser3099
Air Conditioner Related Sensors3101
Structure of Sunlight Sensor3101
Function of Sunlight Sensor3101
Structure of Outside Temperature Sensor3101
Function of Outside Air Temperature Sensor3101
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner3103
Circuit Diagram and Configuration of Connector Pins of Air Conditioner3105
System Diagram of Air Conditioner3107
Input and Output Signals of Air Conditioner Controller3108
Function of Air Conditioner Controller3109
Locations of Air Conditioner Parts and Layout of Connectors3110
Examine Air Leakage (Duct)3119
How to Examine Air Leakage (Duct)3119
Examine Air Conditioner with Self-Diagnosis Function3121
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor3122
Examine Vent (Mode) Changeover3123
How to Examine Vent (Mode) Changeover3123
Examine Fresh/Recirc Air Changeover3124
How to Examine Fresh/Recirc Air Changeover3124
Examine Sunlight Sensor3125
How to Examine Sunlight Sensor3125
Examine Refrigerant (Dual) Pressure Switch3126
How to Examine Refrigerant (Dual) Pressure Switch3126
Examine Relay3128
How to Examine Relay3128
Air Conditioner Troubleshooting Chart 13129
Air Conditioner Troubleshooting Chart 23130
Information Shown in Troubleshooting Table3133
Failure Code [879AKA]3134
Failure Code [879AKB]3135
Failure Code [879BKA]3136
Failure Code [879BKB]3138
Failure Code [879CKA]3140
Failure Code [879CKB]3141
Failure Code [879DKZ]3142
Failure Code [879EMC]3144
Failure Code [879FMC]3145
Failure Code [879GKX]3146
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)3148
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)3150
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)3153
Troubleshooting for Fresh/Recirc Air Changeover3155
Troubleshooting by Gauge Pressure3157
Connect Service Tool3159
How to Connect Service Tool3159
Precautions for Disconnection and Connection of Air Conditioner Piping3161
Handle Compressor Oil3163
Replace Desiccant3165
90 Circuit Diagrams3167
Table of Contents3168
Abbreviation List3169
Hydraulic Circuit Diagram3175
Symbols Used in Hydraulic Circuit Diagram3175
Hydraulic Circuit Diagram3179
Electrical Circuit Diagram3181
Symbols Used in Electric Circuit Diagram3181
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (1/9)3185
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (2/9)3187
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (3/9)3189
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (4/9)3191
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (5/9)3193
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (6/9)3195
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (7/9)3197
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (8/9)3199
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (9/9)3201
Electrical Circuit Diagram (Machine with Gateway Function Controller) (1/11)3203
Electrical Circuit Diagram (Machine with Gateway Function Controller) (2/11)3205
Electrical Circuit Diagram (Machine with Gateway Function Controller) (3/11)3207
Electrical Circuit Diagram (Machine with Gateway Function Controller) (4/11)3209
Electrical Circuit Diagram (Machine with Gateway Function Controller) (5/11)3211
Electrical Circuit Diagram (Machine with Gateway Function Controller) (6/11)3213
Electrical Circuit Diagram (Machine with Gateway Function Controller) (7/11)3215
Electrical Circuit Diagram (Machine with Gateway Function Controller) (8/11)3217
Electrical Circuit Diagram (Machine with Gateway Function Controller) (9/11)3219
Electrical Circuit Diagram (Machine with Gateway Function Controller) (10/11)3221
Electrical Circuit Diagram (Machine with Gateway Function Controller) (11/11)3223
Index3225

IMAGES PREVIEW OF THE MANUAL:

S.M 27/12/24